USER INSTRUCTIONs

User instructions - Shearstream HP - VLENIM0027-01 03.08

®

Valtek ShearStream HP Control Valves Installation

Segmented V-Port Ball Valves Operation
Maintenance


 User instructions - Shearstream HP - VLENIM0027-01 03.08
®

Contents DANGER: Indicates that death, severe personal injury and/

or substantial property damage will occur if proper precau-
1 General Information tions are not taken.
2 Unpacking WARNING: Indicates that danger of death or severe per-
3 Installation
STOP!
sonal injury and/or property damage can occur if proper
precautions are not taken.
4 Quick Check CAUTION: Indicates that minor personal injury and/or seri-
5 Preventative Maintenance ous damage to property can occur if the appropriate pre-
6 Removing Valve From Line cautions are not taken.
NOTE: Indicates and provides additional technical informa-
7 Removing Actuator From Body tion which may not be obvious, even to qualified person-
8 Disassembly and Reassembly nel.
9 Remounting the Actuator Compliance with other notes, which may not be particularly
emphasized, with regard to transport, assembly, operation
Figures and maintenance and with regard to technical documenta-
Figure 1 Body Assembly, >2-inch tion (e.g. in the operating instructions, product documenta-
Figure 2 Body Assembly, 1 – 2-inch tion, or on the product itself) is essential, in order to avoid
faults, which can directly or indirectly cause severe person-
Figure 3 Packing Configurations al injury or property damage..
Figure 4 Seat Configurations
Figure 5 Exploded Body Subassembly 1.4 Protective clothing
Flowserve products are often used in problematic applica-
Tables tions (e.g. under extremely high pressures with dangerous,
Table I Flange Bolting Specifications toxic or corrosive mediums). When performng service, in-
Table II Screwed-in Retainer Torques spection, or repair operations, always ensure that the valve
and the actuator are depressurized and that the valve has
Table III Post/Shaft Plug Torques been cleaned, and that it is free of harmful substances. In
Table IV Optional ShearStream Tools such cases, pay particular attention to personal protection
(e.g. protective clothing, gloves, glasses etc).
Table V Troubleshooting Chart
1.5 Qualified personnel
1 GENERAL INFORMATION Qualified personnel are people who on account of their
1.1 Use education, experience, training, and knowledge of relevant
The following instructions are designed to assist in the standards, specifications, accident prevention, and operat-
unpacking, installation, and maintenance as required for ing conditions have been authorized by those responsible
Flowserve products. Product users and maintenance per- for the safety of the plant to perform the necessary work,
sonnel should thoroughly review this manual prior to in- and recognize and avoid possible dangers.
stalling, operating, or performing any maintenance.
In most cases, Flowserve valves, actuators and accessories 1.6 Spare Parts
are designed for specific applications (e.g. with regard to Use only Flowserve original spare parts. Flowserve cannot
medium, pressure and temperature). For this reason, they accept responsibility for any damages that occur from us-
should not be used in other applications without first con- ing spare parts or fastening materials from other manufac-
tacting the manufacturer. turers. If Flowserve products (especially sealing materials)
have been on store for long periods of time, check them for
1.2 Applicability corrosion or deterioration before putting them into use.
The following instructions are applicable to the mainte-
nance and installation of Valtek ShearStream HP control 1.7 Service / Repair
valves. These instructions cannot claim to cover all details To avoid possible injury to personnel or damage to prod-
of all possible product variations, nor can they provide in- ucts, safety terms must be strictly adhered to. Modify-
formation for every possible example of installation, opera- ing this product, substituting non-factory parts, or using
tion or maintenance. This means that the instructions nor- maintenance procedures other than those outlined in these
mally include only the directions to be followed by qualified Installation, Operation and Maintenance Instructions could
personal using the product for its defined purpose. If there drastically affect performance, be hazardous to personnel
are any uncertainties in this respect, particularly in the and equipment, and may void existing warranties. Between
event of missing product-related information, clarification the actuator and the valve there are moving parts. To avoid
must be obtained via the appropriate Flowserve sales office. injury, Flowserve provides pinch-point-protection in the
Flowserve User Manuals are available at www.flowserve. form of cover plates, especially where side-mounted posi-
com. tioners are fitted. If these plates are removed for inspection,
service or repair special attention is required. After com-
1.3 Terms related to safety pleting work the cover plates must be refitted. Apart from
The terms DANGER, WARNING, CAUTION, NOTE are used the operating instructions and the obligatory accident pre-
in this document to highlight particular dangers and/or to vention directives valid in the country of use, all recognized
provide additional information on points which may not be regulations for safety and good engineering practices must
clearly obvious. be followed.

 User instructions - Shearstream HP - VLENIM0027-01 03.08
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WARNING: Before products are returned to Flowserve for 3.5 Connect the air supply and instrument signal lines. Throt-
STOP!
repair or service, Flowserve must be provided with a cer- tling control valves are equipped with a valve positioner.
tificate that confirms that the product has been decontami- Connections are marked for the air supply and the instru-
nated and is clean. Flowserve will not accept deliveries if a ment signal. Check that the actuator and positioner can
certificate has not been provided (a form can be obtained withstand the maximum air supply from the network. The
from Flowserve). required air supply is indicated on a sticker located on the
actuator. An air regulator will be necessary in certain cases
1.8 Storage in order to limit the supply pressure. A filter is recommend-
In most cases, Flowserve products are manufactured from ed unless the air supplied is exceptionally clean and dry (air
stainless steel. Products not manufactured from stain- quality without humidity, oil, or dust as per IEC 770 and
less steel are provided with an epoxy resin coating. This ISA-7.0.01). All connections must be completely tight.
means that Flowerve products are well protected from cor-
rosion. Nevertheless, Flowserve products must be stored CAUTION: On valves equipped with air filters, the air filter
adequately in a clean, dry, environment. Plastic caps are must point down to perform properly.
fitted to protect the flange faces and prevent the ingress of
foreign materials. These caps should not be removed until 3.6 Use the bolts indicated in Table I for installing the valve in
the valve is actually mounted into the system. the pipeline, and then tighten alternately according to good
practice. The user must in all cases confirm the capacity of
2 Unpacking the bolts to ensure a sufficiently tight gasket seal for the
2.1 While unpacking the valve, check the packing list against expected service conditions.
the materials received. Lists describing the valve and acces-
sories are included in each shipping container.
3.7 Be sure to provide proper overhead clearance for the ac-
tuator to allow for disassembly of the actuator from the
2.2 When lifting the valve from shipping container, use straps
through the yoke legs. Take care to position lifting straps to valve body. Refer to the appropriate to the ShearStream HP
avoid damage to the tubing and mounted accessories. Technical Bulletin for proper clearances. ShearStream HP
Technical Bulletin is available at www.flowserve.com.
WARNING: When lifting a valve be aware that the center of
STOP!
gravity may be above the lifting point. Therefore, support 4 QUICK-CHECK
must be given to prevent the valve from rotating. Failure to Before commissioning, check the control valve by follow-
do so can cause serious injury to personnel and damage to ing these steps:
the valve and nearby equipment.
4.1 Check for full stroke by varying the instrument signal set-
2.3 Contact you shipper immediately if there is shipping damage. tings appropriately. Observe the ball position indicator
located on the actuator or the positioner. The ball should
2.4 Should any problem arise, call your Flowserve representa- change position with a smooth turning movement.
tive.
4.2 Check all air connections for leaks. Tighten or replace any
DANGER: Before installation check the order number, serial leaking lines.
number, and/or the tag number to ensure that the valve and
actuator being installed are correct for the intended applica- 4.3 Check packing box bolting for proper tightness.
tion.
CAUTION: Do not insulate extensions that are provided for CAUTION: Do not overtighten packing. This can cause ex-
hot or cold services. cessive packing wear and high stem friction that may im-
pede shaft movement. After the valve has been in service
3 INSTALLATION for a short period, recheck the packing-box nuts. If the
3.1 Before installing the valve, clean the pipeline of all contami- packing-box leaks, tighten the nuts just enough to stop the
nation, carbon deposits, welding chips, and other foreign leak.
material. Carefully clean gasket surfaces to ensure a tight
seal. Pipelines must be correctly aligned to ensure that the 4.4 Make sure the valve fails in the correct direction in case
valve is not fitted under tension. of air failure. This is done by positioning the valve at mid-
stroke and turning off the air supply and observing the
3.2 Fire protection must be provided by the user. failure direction. If the action is incorrect, see the section
“Reversing the Air-action” in the instructions of the installa-
3.3 Check the direction of fluid flow to ensure that the valve tion, operation and maintenance manual of the appropriate
is correctly installed. Flow direction is indicated by the ar- actuator.
row attached to the body. All installation orientations for fit-
ting the valve into the pipeline are defined at the end of this 5 PREVENTATIVE MAINTENANCE
manual. At least once every six months, check for proper operation
DANGER: To avoid serious injury, keep hands, hair, clothing, by following the preventative maintenance steps outlined
etc away from the ball and seat when the valve is working. below. These steps may be performed while the valve is in-
line and without interrupting service. If an internal problem
3.4 Whenever possible, the valve should be installed so that is suspected, refer to section “Valve Disassembly”.
actuator is in an upright position. Vertical installation of the
actuator permits easier valve maintenance.

 User instructions - Shearstream HP - VLENIM0027-01 03.08
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5.1 Look for signs of gasket leakage through the end flanges Table I: Flange Bolting Specifications
and post. If necessary, re-torque end flanges and post. Valve ANSI Bolt** Torque* (ft.-lbs.)
Size Class Length Low Intermediate
5.2 Examine the valve for damage caused by corrosive fumes (inches) Rating (inches) Strength Strength
or process drippings. 150 2.5 23 61
5.3 Clean the valve and repaint areas of severe oxidation. 1 300 3.0 46 122
600 3.5 46 122
5.4 Check the packing-box for proper tightness. If there is a 150 2.75 23 61
persistent leak, change the packing after referring to sec- 1½ 300 3.5 82 218
tions “Valve Disassembly and Body Reassembly”. 600 4.25 82 218
150 3.25 46 122
CAUTION: Do not overtighten packing. This can cause ex-
cessive packing wear and high friction that may impede 2 300 3.5 46 122
shaft movement. 600 4.25 46 122
150 3.5 46 122
5.5 If the valve is equipped with a lubricator, add lubricant if 3 300 4.25 82 218
necessary. 600 5.0 82 218
5.6 If possible, stroke the valve and check for smooth, full- 150 3.5 46 122
stroke operation. Unsteady shaft movement may indicate 4 300 4.5 82 218
an internal valve problem. 600 5.75 132 353
150 4.0 82 218
5.7 Check the calibration of the positioner. For further prevent- 6 300 4.75 82 218
ative maintenance, see the instructions in the installation,
600 6.75 199 531
operation and maintenance manual for the applicable posi-
tioner. 150 4.25 82 218
8 300 5.5 132 353
5.8 Ensure all accessories, brackets and bolting are securely 600 7.5 296 789
fastened. 150 4.5 132 353
10 300 6.25 199 531
5.9 If possible, remove air supply and observe actuator for cor-
rect fail-safe action. 600 8.5 420 1119
150 4.75 132 353
5.10 Check the actuator and all air connections for leaks. 12 300 6.75 296 789
600 8.75 420 1119
5.11 If an air filter is supplied, check and replace the cartridge if 150 5.50 199 531
necessary. 16 300 7.75 420 1119
600 10.00 667 1760
*Torque values are recommended for low and intermediate strength
bolting per ANSI B16.5 ¶5.3.2. Higher torques may be used with high
strength bolting (ANSI B16.5 ¶5.3.1). In all cases the user must verify
the selected bolting‘s ability to seat the joint under expected operating
condition. Long thru-bolted joints generally require higher strength
bolting and torque values than shorter flanged bolting depending on
operating conditions.
**Lengths are based on ANSI B16.5 stud bolts and raised face ends.


 User instructions - Shearstream HP - VLENIM0027-01 03.08
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Packing Retainer Retainer O-rings Post

(Item No. 88) (Item No. 30) (Item No. 59) (Item No. 123)
Seals* (Item No. 56)
Packing Stud Post O-ring

Inboard End (Item No. 109) Shaft Bearing (Item No. 64)
(Item No. 83) (optional)
Gland Flange
(Item No. 80)
O-ring
(Item No. 61)
Packing Nut
(Item No. 117)

Shaft
(Item No. 51)
Plug
(Item No. 122)
Packing Follower
(Item No. 87) Shaft O-ring
(Item No. 62) Post Bearing
Packing Spacer (optional) (Item No. 84)
(Item No. 93)

Thrust Bearing Body Shaft Pin Ball Post Pin

(Item No. 1) (Item No. 52) (Item No. 50) (Item No. 121)
(Item No. 53)

(*See Figure 4 for seal configurations and item numbers.)

NOTE: Item numbers correspond directly to the valve‘s bill of material.

Refer to it for specific part numbers.

Stationary Post Design

Figure 1: 3 – 12-inch and 16-inch ShearStream HP
Body Assembly with Rotating Post Design
6 Removing Valve From Line
If an internal problem is suspected with the valve and disas- 7.1 Support the actuator assembly before disconnecting it from
sembly is required, remove the valve from the line by proceed- the body assembly.
ing as follows: 7.2 Loosen the actuator adjusting screw to release the spring
WARNING: Depressurize line to atmospheric pressure, compression.
STOP!

drain all process fluids and decontaminate the valve (if 7.3 On Valtek rotary actuators with a clamped lever-arm design,
caustic or hazardous materials are present). Failure to do remove the actuator transfer case cover bolts, carefully pry
so can cause serious injury. or slide the cover plate from the transfer case, then loosen
6.1 Attach a hoist or some means to support the valve. the linkage bolt.
6.2 Remove line bolting. Do not attempt to pry line flanges apart 7.4 Remove bolts connecting yoke to body subassembly.
by pushing or pulling on the valve or actuator. 7.5 Slide the entire actuator assembly off the shaft. On Valtek
6.3 Slide the valve carefully from the line. To avoid damage to the rotary actuators with a clamped lever-arm design, it may be
gasket surfaces, do not twist the valve. necessary to wedge the splined lever arm apart to loosen it
6.4 After the valve is completely removed from the line, slowly from the shaft splines.
relieve air pressure from the actuator.
8 DISASSEMBLY AND REASSEMBLY
7 Removing Actuator From Body 8.1 Disassembling the Body
Sizes 3 – 12-inch and 16-inch ShearStream valves are de- Removing the actuator from the body assembly to disas-
signed to be disassembled without removing the Flowserve semble 3 – 12-inch and 16-inch bodies is not necessary;
actuator, however, removing the actuator is recommended. however, this procedure is recommended. On valves with
Refer to actuator installation, operation, maintenance instruc- the clamped lever-arm design loosening the valve shaft from
tions, and proceed as follows:

 User instructions - Shearstream HP - VLENIM0027-01 03.08
®

Inboard End Packing Shaft Bearing
(Item No. 88) (Item No. 83) Retainer Retainer O-rings
(Item No. 30) (Item No. 59) Post
Packing Stud Seals*
(Item No. 56) (Item No. 123)
(Item No. 109)
Post O-ring
(Item No. 64)
Gland Flange (optional)
(Item No. 80)

Packing Nut Plug

(Item No. 117) (Item
No. 122)

Shaft
(Item No. 51)

Packing Follower O-ring

(Item No. 87) (Item No. 61)

Packing Spacer
(Item No. 93)
Pin Ball Post Bearing Thrust Bearing

Body (Item No. 52) (Item No. 50) (Item No. 84) (Item No. 53)

(Item No. 1)

(*See Figure 4 for seal configurations and item numbers.)

NOTE: Item numbers correspond directly to the valve‘s bill of material. Refer to it for specific part numbers.

Figure 2: 1 – 2-inch ShearStream HP Body Assembly

the actuator prior to body disassembly is necessary. Refer when they are removed from the valve. Carefully remove the
to Figures 1, 2 and 5 and proceed as follows: shaft plug and O-ring and finally the rotating post. (Inserting
8.1.1 Remove the seal retainer and seals. a bolt in the jack screw hole, tapped in the post, will help in
removing the post.)
Screw-in style – This requires loosening the retainer by
On stationary post designs, drive the shaft pin into the
turning it counterclockwise and removing it from the body.
center of the shaft until the outward end of the pin clears the
(A special cross-wrench tool may be ordered from the fac-
ball splines. Be careful to not damage the shaft. The pin can
tory. See Table IV.) Remove the metal seals. Remove the
then be punched out of the shaft after the shaft is removed.
soft seal if applicable.
Remove the anti-rotation clamp. Remove the post and the
Lock-ring style – Some valve designs have a retaining ring post O-rings.
held in with set screws. To remove it, loosen the set screws
in the lock ring, then remove the retaining ring, lock ring 8.1.4 On 3 – 12-inch and 16-inch designs, remove the shaft by
and finally the seal retainer. If the lock ring set screws will pulling it out through the outboard end of the body. On 1
not loosen, the retaining ring can be forced out using a – 2-inch designs, remove the shaft by pulling it out through
flat-headed screwdriver and pliers. Remove the seals. the inboard end of the body
8.1.2 Remove the gland flange by removing both packing nuts. CAUTION: Take special care to not damage the splined end
Removing the studs is not necessary. of valve shaft during disassembly.
8.1.3 On rotating post designs, drive both the shaft and post pins 8.1.5 Rotate the ball inside the body so the non-splined end of
into the center of the shaft and post until the outward end of the ball is toward the back port of the valve and remove the
the pin clears the ball. Be careful to not damage the shaft or ball straight out of the body. If necessary, on stationary post
post. The pins can then be punched out of the shaft and post designs remove the post bearing from the ball by pushing it
out with a press.

 User instructions - Shearstream HP - VLENIM0027-01 03.08
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SureGuard Standard Standard Twin "V"

Single "V" Twin Square

SafeGuard Live-loading SafeGuard / SureGuard Twin Square Twin "V"

(packing studs Fire-safe Option with Lubricator with Lubricator
rotated 45 degrees)
(live-loading omitted)

Figure 3: ShearStream HP Packing Configurations

CAUTION: Be extremely careful not to gall or scratch the 8.2.5 Position the ball in the body by lowering it, splined hole first,
sealing surface of the ball when removing it from body. into the back of the body. Rotate the ball surface toward the
Scratches may later cause excessive leakage and seal front of the body so that the splined hole is toward the packing
wear. box.
8.1.6 Push packing and bearings out of the body using a bronze CAUTION: Be extremely careful not to gall or scratch the
dowel with the appropriate diameter. Push packing out of the sealing surface of the ball when replacing it in the body.
body from the center of the valve. (See Table IV for optional Scratches may later cause excessive leakage and seal
shaft/post bearing tool.) wear.
8.2 Reassembling the Body 8.2.6 On 3 – 12-inch and 16-inch designs, insert the shaft through
the outboard end of body and through the splined hole of
To reassemble the body subassembly, refer to Figures 1 or
the ball into the packing box. On 1 – 2-inch designs, insert
2, 3, 4, and 5 and proceed as follows:
the shaft through the inboard end of body and through the
8.2.1 Clean all parts and replace all O-rings and soft seals. packing box into the splined hole of ball. (For 1-inch body
8.2.2 Check the ball sealing surface to make sure it is smooth and designs, the thrust bearing, packing spacer, packing, and
free of scoring and scratches. packing follower must be inserted before installing shaft.)
CAUTION: Damaged or dirty seal surfaces can cause exces- 8.2.7 Position the shaft so that the pin hole in the shaft and ball are
sive seat wear and high torque requirements. Damaged in alignment. (Some shafts have a half circle mark and line
balls should be replaced. on the end. Align the line mark with the pin and the half circle
symbol with the ball.) Install the shaft pin and drive it firmly
8.2.3 Inspect the shaft and post for scratches or galled surfaces. For into place so that half is in the ball and half in the shaft.
maximum performance, ShearStream shafts and posts are
8.2.8 On rotating post designs, Insert the post through the outboard
machined to a very smooth finish. If damage exists, replace
end of the body and into the hole of the ball. (For 1 – 2-inch valves
the shaft or contact the factory representative.
sizes, insert thrust bearing before installing post.) Position the
NOTE: Ball and shaft are interchangeable. Replacing the ball post so that the pin hole in the post and ball are aligned. (For
does not require replacing the shaft. 6 – 12-inch and 16-inch valve sizes, be certain that the ball
8.2.4 Using a press to install new bearings in the body and/or ball pin hole is aligned with the smallest diameter pin hole in the
is recommended. (An optional post/bearing tool is available post. Some posts have a half circle mark on the end. Align
from the factory. See Table IV.) When correctly installed, the this mark with the ball.) Install the post pin and drive it firmly
ends of the body bearings should be flush with the inside of into place so that half is in the ball and half is in the post.
the body. Torque the plug per Table II.


 User instructions - Shearstream HP - VLENIM0027-01 03.08
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Metal Seals Metal Seals

Retainer Body Retainer Body

Ball Ball Ball

Pressure Secondary
energizes seal seal locks primary
to flex into ball seal to ball

Metal seat: shaft downstream* Metal seat: shaft upstream*

Metal Seal
Soft Seal Soft Seal

Retainer / Flow ring Retainer

Body Body

Ball Ball

Soft seat and flow ring Dual*

Body Body

Retainer Retainer

Seat Seat keeper

Soft Seal

Wave Springs Wave Springs

Ball Ball

Heavy duty metal seat Heavy duty soft seat

* For sizes 1 inch and 1.5 inch there is only one metal seal ring

Figure 4: Seat Configurations


 User instructions - Shearstream HP - VLENIM0027-01 03.08
®

On stationary post designs, Ensure that the post Table II: Post/Shaft Plug Torques (ft.-lbs.)
and post threads are well lubricated with a high
temperature bearing grease (or as required by the Valve Size Rotating Post Design
application) before installation. Replace the post (inches) (Shaft Plug)
O-ring and reinstall the post. Torque the post per Table II. 1, 1.5* 50
Install the anti-rotation clamp kit.
2* 85
8.2.9 Slide thrust bearing, packing spacer, packing, and packing
follower over the splined end of the shaft and into body. 3, 4 150
Typical packing configurations are shown in Figure 3. (1-inch 6,8 250
designs refer to Step 6.)
10, 12 300
NOTE: Always use new packing whenever rebuilding the
packing box. 16* N/A
CAUTION: Since the sealing on V-ring packing takes place * Flanged post; torque values not required.
at the feather edge, it is imperative to avoid damage to
that edge. Table III.
8.2.10 Reinstall the gland flange and packing nuts and leave 8.2.15 On some 10, 12 and 16-inch valves where the retainer is held
loose. in place with set screws, reinsert the lock ring into the body
CAUTION: Do not overtighten packing. This can cause with the words ‘Ball Side’ facing toward the ball. The lock
excessive packing wear and shaft friction, which may ring has ‘Ball Side’ and ‘Port Side’ marked on it. Insert the
impede shaft rotation. retaining ring into the inner groove of the body, being certain
8.2.11 Place the valve on a flat surface with the threaded (retainer) it is fully seated. Tighten the lock ring setscrews evenly to a
port facing up and pull the shaft toward the actuator until it torque of 225 inch-pounds.
is fully against the thrust bearing.
8.2.16 After the seal retainer is in tight, tighten the packing nuts
8.2.12 On 3 – 12-inch and 16-inch designs, make certain the just over finger-tight. Packing nuts should be tightened as
ball surface is facing up and position the ball as close as necessary to prevent stem leakage.
possible in the center of the body‘s inside diameter. (The
pinned connection between the ball and shaft is not a tight
connection; the design includes a considerable amount of CAUTION: Do not overtighten packing. This can cause
axial play between the ball and shaft.) excessive packing wear and high shaft friction, which may
retard shaft rotation.
On 1 – 2-inch designs, make certain the ball surface is fac-
ing up and pull on the shaft until the post is fully against the 9 Remounting the Actuator
thrust bearing. (The ball does not self center. No axial play
Before mounting a Flowserve actuator on the valve body,
should occur between the ball and shaft.)
verify that the ball rotation matches the actuator rotation
8.2.13 Replace the seat as applicable to the valve. (Refer to Figure 4.) and complies with the air failure requirements. Procedure
For metal seats, insert the two metal seal rings into the body. for mounting the actuator is as follows:
(See
note on Figure 4.) 9.1 Slide the entire actuator assembly onto the shaft. (If neces-
For soft seats, insert the soft seal ring into the body. sary on Flowserve actuator designs with clamped lever-arm
design, wedge the splined lever arm apart to loosen it on the
For dual seats, insert the soft seal ring, followed by the
shaft splines.)
two metal seal rings into the body. (See note on Figure 4.)
9.2 Bolt the yoke to the valve body.
For heavy duty metal seats or heavy duty soft seats, first 9.3 Position the actuator lever arm on the shaft so the actuator
lubricate the seat o-ring and install into the seat. Next lu- stem is centered in the transfer case.
bricate the mating surfaces between the seat and seat re-
9.4 On clamped lever-arm actuator designs, firmly tighten the
tainer. Then place one shim in the retainer, followed by all
linkage bolt. Bolt the transfer case cover plate into place.
of the wave springs, and then the remaining shims. Next
place the seat into seat retainer, so the seat is resting on 9.5
Align the stroke indicator plate on the end of spline lever so
the shims and wave springs. For heavy duty metal seats, it accurately indicates ball position.
lubricate the contact surfaces between the seat and ball.
Follow instructions in 8.2.14 for simultaneously installing CAUTION: On clamped lever-arm actuators, never apply air
the seat retainer and heavy duty seat into the body. to the actuator without the cover plate installed; otherwise,
the unsupported shaft may sustain damage.
8.2.14 With screwed-in retainer designs, replace the
O-rings in the retainer (except on high temperature valves, 9.6 Install valve in line as outlined in Installation section.
which do not use O-rings). Refer to Figure 1 or 2. Lubricate
the retainer threads and rings and reinstall the retainer in
the front of the body. Torque the seal retainer according to

 User instructions - Shearstream HP - VLENIM0027-01 03.08
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End Flange
(Item No. 10)

End Plug (Item No. 122)

End Plug O-ring (Item No. 61)
Post (Item No. 123)
Seal Rings Half Ring
(Item No. 20) (Item No. 11)
Shaft (Item No. 51)

Body
(Item No. 1)
Seal Retainer (Item No. 30)
Retainer O-ring (Item No. 59)
Ball Retainer O-ring (Item No. 56)
Post Bearing (Item No. 50)
(Item No. 84) Soft Seal Insert (Item No. 21)
Post Pin
(Item No. 121) Yoke Bolt (Item No. 107)
End Flange Thrust Bearing (Item No. 53)
(Item No. 10) Packing Spacer (Item No. 93)
Packing Follower (Item No. 87)
Half Ring
Gland Flange (Item No. 80)
(Item No. 11)
Shaft Pin Shaft Bearing Gland Flange Stud (Item No. 109)
(Item No. 83)
(Item No. 52) Packing Gland Flange Nut
(Item No. 88) (Item No. 117)

Figure 5: Exploded Body Subassembly, 3 – 12-inch and 16-inch Rotating Post Design
NOTE: Item numbers correspond directly to the valve‘s bill of material. Refer to it for specific part numbers.

Table III: Screwed-in Retainer Torques Table IV: Optional ShearStream Tools
Valve Torque Valve Torque Valve Size Retainer Shaft/Post
Size Value Size Value (inches) Tool Bearing Tool
(inches) (ft.-lbs.) (inches) (ft.-lbs.) 1 87377 76891
1, 1.5, 2 150-175 8, 10 650-700 1.5 87530 76509
3 250-300 12 900-950 2 76112 76509
4, 6 550-600 16* N/A 3 62295 75970
* Clamped design; torque value not required. 4 62294 75970
6 62296 81978 / 81974
8 62336 81978 / 81974
10 81775 76550 / 76551
12 81034 76550 / 76551
16 N/A* 97967 / 97966
* Clamped design; retainer tool not required.

10
 User instructions - Shearstream HP - VLENIM0027-01 03.08
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Table V: Troubleshooting ShearStream Ball Valves

Failure Probable Cause Corrective Action
Valve moves to failure position, 1 Failure of actuator stem O-ring 1 Replace actuator stem O-ring
excessive air bleeding from
2 Failure of sliding seal assembly 2 Repair or replace stem adapter/
transfer case
linkage assembly
Jerky shaft rotation 1 Overtightened packing box 1 Retighten packing box nut to slightly
over finger-tight

2 Improper adjustment of lever arm on 2 Readjust lever arm; see actuator

shaft causing arm to contact transfer maintenance instructions
case, thus failing to convert torque

3 Actuator cylinder wall not lubricated 3 Lubricate actuator cylinder wall with
silicone lubricant

4 Worn piston O-ring allowing piston 4 Replace O-ring; if galling occurred,

to gall on cylinder wall replace all damaged parts

5 Worn actuator stem O-ring causing 5 Replace O-ring; if actuator stem is

actuator stem to gall on stem collar galled, replace it

6 Worn (or damaged) thrust bearing, 6 Disassemble and inspect parts; replace
shaft bearing or packing followers any worn or damaged parts

Excessive leakage 1 Improper adjustment of external 1 Adjust the external stroke stops; see
through seal stroke stops on actuator maintenance instructions

2 Worn or damaged seal 2 Replace seal

3 Damaged ball sealing surface 3 Replace ball (and shaft, if worn)
4 Improper handwheel adjustment 4 Adjust handwheel until ball seals properly
acting as limit-stop

5 Ball not centered in body I.D. 5 Center ball; replace damaged seals
Leakage through 1 Dirty line gasket surfaces 1 Clean gasket surfaces, reinstall valve
line flanges
2 Worn gaskets 2 Replace gaskets
3 Improper torque on line flanges 3 Tighten line flanges evenly and comp-
letely (see Table I for proper torque)

4. Flange or pipe misalignment 4 Realign flanged ends with piping

Leakage through packing box 1 Loose packing box nuts 1 Tighten packing box nuts over finger-tight
2 Worn or damaged packing 2 Replace packing
3 Dirty or corroded packing box 3 Clean body bore, stem, replace packing
Valve slams, won’t open, or 1 Improper valve installation 1 See step 2 in the “Installation”
causes severe water hammer section and correct flow direction

Shaft rotates, ball remains open 1 Broken shaft 1 Replace shaft

or closed

Actuator operates, shaft does 1 Broken internal actuator parts 1 Refer to appropriate actuator
not rotate maintenance instructions

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 User instructions - Shearstream HP - VLENIM0027-01 03.08
®

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